Caloric Heat Pump Ice Making Appliance

ABSTRACT

An appliance includes an ice maker and a caloric heat pump system for cooling the ice maker. The caloric heat pump system includes a pump for circulating a heat transfer fluid between first and second heat exchangers and caloric material stages in order to cool the ice maker with the first heat exchanger. A related ice making appliance is also provided.

FIELD OF THE INVENTION

The present subject matter relates generally to ice making appliances, such as stand-alone ice making appliances.

BACKGROUND OF THE INVENTION

Ice makers generally produce ice for the use of consumers, such as in drinks being consumed, for cooling foods or drinks to be consumed and/or for other various purposes. Certain refrigerator appliances include ice makers for producing ice. The ice maker can be positioned within the appliances' freezer chamber and direct ice into an ice bucket where it can be stored within the freezer chamber. Such refrigerator appliances can also include a dispensing system for assisting a user with accessing ice produced by the refrigerator appliances' ice maker. However, the incorporation of ice makers into refrigerator appliance can have drawbacks, such as limits on the amount of ice that can be produced and the reliance on the refrigeration system of the refrigerator appliance to form the ice. Recently, stand-alone ice makers have been developed. These ice makers are separate from refrigerator appliances and provide independent ice supplies. However, typical stand-alone ice makers are expensive, to the point of being cost-prohibitive to the typical consumer.

Refrigerators and stand-alone ice makers frequently utilize heat pumps to cool liquid water and form ice. Conventional sealed system technology typically utilizes a heat pump that relies on compression and expansion of a fluid refrigerant to receive and reject heat in a cyclic manner so as to effect a desired temperature change or i.e. transfer heat energy from one location to another. This cycle can be used to provide e.g., for the receiving of heat from the environment and the rejecting of such heat elsewhere. A variety of different fluid refrigerants have been developed that can be used with the heat pump in such systems.

While improvements have been made to such heat pump systems that rely on the compression of fluid refrigerant, at best such can still only operate at about forty-five percent or less of the maximum theoretical Carnot cycle efficiency. Also, some fluid refrigerants have been discontinued due to environmental concerns. The range of ambient temperatures over which certain refrigerant-based systems can operate may be impractical for certain locations. Other challenges with heat pumps that use a fluid refrigerant exist as well.

Accordingly, ice makers with features for efficiently cooling water would be useful. In particular, a stand-alone ice maker with features for efficiently cooling water without requiring compression of fluid refrigerant would be useful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides an appliance. The appliance includes an ice maker and a caloric heat pump system for cooling the ice maker. The caloric heat pump system includes a pump for circulating a heat transfer fluid between first and second heat exchangers and caloric material stages in order to cool the ice maker with the first heat exchanger. A related ice making appliance is also provided. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In a first exemplary embodiment, an ice making appliance is provided. The ice making appliance includes a casing. An auger is disposed within the casing. A motor is coupled to the auger. The motor is operable to rotate the auger within the casing. A first heat exchanger is coupled to the casing for receiving heat from the casing. The ice making appliance also includes a second heat exchanger. A caloric heat pump system is configured for cooling the casing with the first heat exchanger. The caloric heat pump system includes a plurality of caloric material stages. A field generator is positioned proximate the caloric material stages. The field generator is positioned such that the caloric material stages are moved in and out of a field of the field generator during operation of the caloric heat pump system. The caloric heat pump system also includes a pump for circulating a heat transfer fluid between the first and second heat exchangers and the caloric material stages.

In a second exemplary embodiment, an appliance is provided. The appliance includes an ice maker. A first heat exchanger is coupled to the ice maker for receiving heat. The appliance also includes a second heat exchanger. A caloric heat pump system is configured for cooling the ice maker with the first heat exchanger. The caloric heat pump system includes a plurality of caloric material stages. A field generator is positioned proximate the caloric material stages. The field generator is positioned such that the caloric material stages are moved in and out of a field of the field generator during operation of the caloric heat pump system. The caloric heat pump system also includes a pump for circulating a heat transfer fluid between the first and second heat exchangers and the caloric material stages.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

FIG. 1 provides a perspective view of an ice making appliance in accordance with an exemplary embodiment of the present subject matter.

FIG. 2 provides a perspective, section view of the exemplary ice making appliance of FIG. 1.

FIG. 3 provides a rear, perspective view of the exemplary ice making appliance of FIG. 1 with a casing of the exemplary ice making appliance removed.

FIG. 4 provides a schematic view of certain components of the exemplary ice making appliance of FIG. 1.

FIG. 5 provides a perspective view of a heat pump according to an exemplary embodiment of the present subject matter.

FIG. 6 provides an exploded view of the exemplary heat pump of FIG. 5.

FIG. 7 provides a section view of the exemplary heat pump of FIG. 5.

FIG. 8 provides perspective view of the exemplary heat pump of FIG. 5.

FIG. 9 provides a schematic representation of various steps in the use of a stage of the exemplary heat pump of FIG. 5.

FIG. 10 provides another schematic representation of various steps in the use of a stage of the exemplary heat pump of FIG. 5.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

The present subject matter is directed to an ice maker coupled with a caloric heat pump system for heating or cooling water within the ice maker. While described in greater detail below in the context of a magneto-caloric heat pump system, one of skill in the art will recognize that other suitable caloric materials may be used in a similar manner to heat or cool water within the ice maker, i.e., apply a field, move heat, remove the field, move heat. For example, electro-caloric material heats up and cools down within increasing and decreasing electric fields. As another example, elasto-caloric material heats up and cools down when exposed to increasing and decreasing mechanical strain. As yet another example, baro-caloric material heats up and cools down when exposed to increasing and decreasing pressure. Such materials another other similar caloric materials may be used in place of or in addition to the magneto-caloric material described below to heat or cool water within the ice maker. Thus, caloric material is used broadly herein to encompass materials that undergo heating or cooling when exposed to a changing field from a field generator, where the field generator may be an electric field generator, an actuator for applying mechanical stress or pressure, etc.

Referring now to FIG. 1, one embodiment of an ice making appliance 10 in accordance with an exemplary embodiment of the present subject matter is illustrated. In FIG. 1, ice making appliance 10 is configured as a stand-alone ice making appliance. Thus, as discussed in greater detail below, ice making appliance 10 need not be plumbed to a pressurized water supply, such as a well or municipal water supply, to operate. However, it should be understood that the present subject matter is not limited to any particular type or style of ice maker or ice making appliance. For example, the present subject matter may be used in or with ice making appliances that are plumbed into pressurized water supplies to receive liquid water during operation. As another example, the present subject matter may be used to assist with cooling the ice maker described in U.S. Pat. No. 8,171,744 of Watson et al. or the ice maker described in U.S. Pat. No. 8,459,047 of Hall et al., both of which are incorporated by reference herein in their entirety. Thus, the present subject matter may also be used to cool crescent-cube style ice makers, dip tube or finger-style ice makers, auger-style ice makers or any other suitable style of ice maker in order to form ice from liquid water. Also, the present subject matter may be used within refrigerator appliances in order to cool water and form ice within ice makers of the refrigerator appliances. Accordingly, it should be understood that the present subject matter is not limited to the exemplary ice making appliance 10 illustrated in FIG. 1.

As shown, ice making appliance 10 includes an outer housing 12 which generally at least partially houses various other components of ice making appliance 10 therein. A container 14 is also illustrated. Container 14 defines a first storage volume 16 for receipt and storage of ice 18. A user of ice making appliance 10 may access ice 18 within container 14 for consumption or other uses. Container 14 may include one or more sidewalls 20 and a base wall 22 (see FIG. 2), which may together define first storage volume 16. In exemplary embodiments, at least one sidewall 20 may be formed from a clear, see-through (i.e. transparent or translucent) material, such as a clear glass or plastic, such that a user can see into first storage volume 16 and thus view ice 18 therein. Further, in exemplary embodiments, container 14 may be removable, such as from outer housing 12, by a user. This facilitates easy access by the user to ice within container 14 and further, for example, may provide access to a water tank 24 (see FIG. 2) of ice making appliance 10.

As discussed above, ice making appliance 10 may be a stand-alone ice making appliance, and thus are not connected to a refrigerator or other appliance. Additionally, in exemplary embodiments, ice making appliance 10 is not connected to plumbing or another water source that is external to ice making appliance 10, such as a refrigerator water source. Rather, in exemplary embodiments, water is initially supplied to ice making appliance 10 manually by a user, such as by pouring water into water tank 24. The stand-alone features may reduce costs associated with ice making appliance 10 and allows the consumer to position ice making appliance 10 at any suitable desired location, with the only requirement in some embodiments being access to an electrical source. Removable container 14 allows easy access to ice and allows container 14 to be moved to a different position from the remainder of ice making appliance 10 for ice usage purposes. Additionally, in exemplary embodiments, ice making appliance 10 may be configured to make nugget ice (as discussed herein) which is becoming increasingly popular with consumers.

Referring to FIGS. 2 and 3, various other components of ice making appliances 10 are illustrated. For example, as mentioned, ice making appliance 10 includes a water tank 24. Water tank 24 defines a second storage volume 26 for receipt and holding of liquid water. Water tank 24 may include one or more sidewalls 28 and a base wall 30 which may together define second storage volume 26. In exemplary embodiments, water tank 24 may be disposed below container 14 along a vertical direction V defined for ice making appliance 10, as shown.

As discussed, in exemplary embodiments, liquid water is provided to water tank 24 for use in forming ice. Accordingly, ice making appliance 10 may further include a pump 32. Pump 32 may be in fluid communication with second storage volume 26. For example, liquid water may be flowable from second storage volume 26 through an opening 31 defined in water tank 24, such as in a sidewall 28 thereof, and may flow through a conduit to and through pump 32. Pump 32 may, when activated, actively flow liquid water from second storage volume 26 therethrough and from pump 32.

Liquid water actively flowed from pump 32 may be flowed (for example through a suitable conduit) to a reservoir 34. For example, reservoir 34 may define a third storage volume 36, which may be defined by one or more sidewalls and a base wall, in the same or similar manner to water tank 24. Third storage volume 36 may, for example, be in fluid communication with pump 32 and may thus receive liquid water that is actively flowed from water tank 24, such as through pump 32. Reservoir 34 and third storage volume 36 thereof may receive and contain liquid water to be provided to an ice maker 50 for the production of ice. Accordingly, third storage volume 36 may be in fluid communication with ice maker 50. For example, liquid water may be flowed, such as through suitable conduits, from third storage volume 36 to ice maker 50.

Ice maker 50 generally receives liquid water, such as from reservoir 34, and freezes the water to form ice 18. While any suitable style of ice maker is within the scope and spirit of the present disclosure, in exemplary embodiments, ice maker 50 is a nugget ice maker, and in particular is an auger-style ice maker. As shown, ice maker 50 includes a casing 52 into which liquid water from third storage volume 36 is flowed. Casing 52 is thus in fluid communication with third storage volume 36. For example, casing 52 may include one or more sidewalls 54 which may define an interior volume 56, and an opening (not shown) may be defined in a sidewall 54. Water may be flowed from third storage volume 36 through the opening in sidewall 54 (such as via a suitable conduit) into interior volume 56.

An auger 60 is disposed at least partially within casing 52, e.g., such that auger 60 is rotatable within casing 52. In particular, a motor 61 is coupled to auger 60. For example, auger 60 may be mounted or fixed to a shaft of motor 61. Motor 61 is operable to rotate auger 60 within casing 52. Thus, when motor 61 is on, auger 60 rotates within casing 52, and auger 60 may be stationary within casing 52 when motor 61 is off. Liquid water within casing 52 may at least partially freeze due to heat exchange, such as with a heat pump system 100 as discussed herein. The at least partially frozen water may be lifted by auger 60 within casing 52. In particular, auger 60 may scrape the at least partially frozen water from an inner surface of casing 52 and lift the scraped at least partially frozen water upwardly within casing 52. Further, in exemplary embodiments, the at least partially frozen water may be directed by auger 60 to and through an extruder 62. Extruder 62 may extrude the at least partially frozen water to form ice, such as nuggets of ice 18.

Formed ice 18 may be provided by ice maker 50 to container 14, and may be received in first storage volume 16 thereof. For example, ice 18 formed by auger 60 and/or extruder 62 may be provide to container 14. In exemplary embodiments, ice making appliance 10 may include a chute 70 for directing ice 18 produced by ice maker 50 towards first storage volume 16. For example, as shown, chute 70 is generally positioned above container 14 along the vertical direction V. Thus, ice can slide off of chute 70 and drop into storage volume 16 of container 14. Chute 70 may, as shown, extend between ice maker 50 and container 14, and may include a body 72 which defines a passage 74 therethrough. Ice 18 may be directed from ice maker 50 (such as from auger 60 and/or extruder 62) through passage 74 to container 14. In some embodiments, for example, a sweep 64, which may for example be connected to and rotate with auger 60, may contact the ice emerging through extruder 62 from auger 60 and direct the ice through passage 74 to container 14.

As discussed, water within casing 52 may at least partially freeze due to heat exchange, such as with a heat pump system 100. Thus, ice maker 50 includes heat pump system 100 for cooling ice maker 50. Heat pump system 100 is in thermal communication with casing 52 to remove heat from casing 52 and interior volume 56 thereof, thus facilitating freezing of water therein to form ice. As shown in FIG. 3, heat pump system 100 includes a first heat exchanger 104 in thermal communication with casing 52 in order to remove heat from interior volume 56 and water therein during operation of heat pump system 100. For example, first heat exchanger 104 may at least partially surround casing 52. In particular, first heat exchanger 104 may be a conduit coiled around and in contact with casing 52, such as the sidewall(s) 54 thereof. Heat pump system 100 and components thereof are discussed in greater detail below, in the context of FIG. 4.

As discussed, in exemplary embodiments, ice 18 may be nugget ice. Nugget ice is ice that that is maintained or stored (i.e. in first storage volume 16 of container 14) at a temperature greater than the melting point of water or greater than about thirty-two degrees Fahrenheit. Accordingly, the ambient temperature of the environment surrounding the container 14 may be at a temperature greater than the melting point of water or greater than about thirty-two degrees Fahrenheit. In some embodiments, such temperature may be greater than forty degrees Fahrenheit, greater than fifty degrees Fahrenheit, or greater than sixty degrees Fahrenheit.

Ice 18 held within the first storage volume 16 may gradually melt. The melting speed is increased for nugget ice due to the increased maintenance / storage temperature. Accordingly, drain features may advantageously be provided in container 14 for draining such melt water. Additionally, and advantageously, the melt water may in exemplary embodiments be reused by ice making appliance 10 to form ice.

In exemplary embodiments, ice making appliance 10 may further include a controller 90. Controller 90 may for example, be configured to operate ice making appliance 10 based on, for example, user inputs to ice making appliance 10 (such as to a user interface thereof), inputs from various sensors disposed within ice making appliance 10, and/or other suitable inputs. Controller 90 may for example include one or more (e.g., non-transitory) memory devices and one or more microprocessors, such as general or special purpose microprocessors operable to execute programming instructions or micro-control code associated with ice making appliance 10 operation. The memory may represent random access memory such as DRAM, or read only memory such as ROM or FLASH. In one embodiment, the processor executes programming instructions stored in memory. The memory may be a separate component from the processor or may be included onboard within the processor. Alternatively, controller 90 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND gates, and the like) to perform control functionality instead of relying upon software.

In exemplary embodiments, controller 90 may be in operative communication with pump 32. Such operative communication may be via a wired or wireless connection, and may facilitate the transmittal and/or receipt of signals by controller 90 and pump 32. Controller 90 may be configured to activate pump 32 to actively flow liquid water. For example, controller 90 may activate pump 32 to actively flow water therethrough when, for example, reservoir 34 requires water. A suitable sensor(s), for example, may be provided in the third storage volume 36. The sensor(s) may be in operative communication with controller 90 may be transmit signals to controller 90 which indicate whether or not additional water is desired in reservoir 34. When controller 90 receives a signal that water is desired, controller 90 may send a signal to pump 32 to activate pump 32.

FIG. 4 provides a schematic view of certain components of ice making appliance 10 including casing 52 and machinery compartment 140. As shown in FIG. 4, ice making appliance 10 includes heat pump system 100 for heating and/or cooling casing 52. Heat pump system 100 includes a pump 102, first heat exchanger 104, a heat pump 106 and a second heat exchanger 108. Various components of heat pump system 100 may be positioned within machinery compartment 140 below casing 52, including pump 102, heat pump 106 and second heat exchanger 108, e.g., while first heat exchanger 104 is positioned on or at casing 52 above machinery compartment 140.

First heat exchanger 104 is assembled in a heat exchange relationship with casing 52 in order to heat and/or cool interior volume 56 of casing 52 during operation of heat pump system 100. Thus, first heat exchanger 104 may be positioned at or adjacent casing 52 for the rejection of heat from and/or addition of heat into interior volume 56 of casing 52. A heat transfer fluid such as e.g., an aqueous solution, flowing within first heat exchanger 104 receives heat from interior volume 56 of casing 52 thereby cooling its contents and/or rejects heat to interior volume 56 of casing 52 thereby heating its contents. As an example, first heat exchanger 104 may be a conduit, such as copper or aluminum tubing, wound onto casing 52 at an outer surface 84 of casing 52. When first heat exchanger 104 is a conduit wound onto casing 52, first heat exchanger 104 may be brazed, soldered, clipped, adhered or otherwise suitably mounted to casing 52 at outer surface 84 of casing 52.

First heat exchanger 104 extends between a first inlet 130 and a second inlet 132. The heat transfer fluid from heat pump 106 may enter first heat exchanger 104 at first inlet 130 of first heat exchanger 104 and may exit first heat exchanger 104 at second inlet 132 of first heat exchanger 104 in a heating mode. Conversely, in a cooling mode, the heat transfer fluid from heat pump 106 may enter first heat exchanger 104 at second inlet 132 of first heat exchanger 104 and may exit first heat exchanger 104 at first inlet 130 of first heat exchanger 104. First inlet 130 of first heat exchanger 104 may be positioned at or proximate a top portion 80 of casing 52. Conversely, second inlet 132 of first heat exchanger 104 may be positioned at or proximate a bottom portion 82 of casing 52. Thus, first inlet 130 of first heat exchanger 104 may be positioned above second inlet 132 of first heat exchanger 104 along the vertical direction V on casing 52. In such a manner, the heat transfer fluid within first heat exchanger 104 may first heat top portion 80 of casing 52 before flowing downwardly along the vertical direction V to heat bottom portion 82 of casing 52 in the heating mode. Conversely, in the cooling mode, the heat transfer fluid within first heat exchanger 104 may first cool bottom portion 82 of casing 52 before flowing upwardly along the vertical direction V to cool top portion 80 of casing 52. In such a manner, efficient heat transfer between the heat transfer fluid within first heat exchanger 104 and interior volume 56 of casing 52 may be facilitated.

First heat exchanger 104 may be wound onto casing 52 between first and second inlets 130, 132 of first heat exchanger 104. As an example, first heat exchanger 104 may be wound onto casing 52 such that adjacent windings of first heat exchanger 104 are spaced apart from one another along the vertical direction V on outer surface 84 of casing 52, as shown in FIG. 4. In particular, adjacent windings of first heat exchanger 104 may be uniformly spaced apart from one another along the vertical direction V on outer surface 84 of casing 52. Thus, first heat exchanger 104 may be wound onto outer surface 84 of casing 52 at a constant rate. By uniformly spacing adjacent windings of first heat exchanger 104 on outer surface 84 of casing 52, uniform heat transfer between the heat transfer fluid within first heat exchanger 104 and interior volume 56 of casing 52 along the vertical direction V may be facilitated.

Operation of heat pump system 100 in the cooling mode is described in greater detail below. In the cooling mode, the heat transfer fluid flows out of first heat exchanger 104 by line 120 to heat pump 106 after cooling wash chamber 106 of tub 104. As will be further described herein, the heat transfer fluid receives additional heat from magneto-caloric material (MCM) in heat pump 106 and then flows by line 124 to pump 102 and then to second heat exchanger 108, e.g., that is disposed within machinery compartment 140. The heat transfer fluid within second heat exchanger 108 rejects heat to the environment, machinery compartment 140, and/or another location external to wash chamber 106 of tub 104 via second heat exchanger 108. A fan 112 may be used to create a flow of air across second heat exchanger 108 and thereby improve the rate of heat transfer from the environment.

From second heat exchanger 108, the heat transfer fluid returns by line 122 to heat pump 106 where, as will be further described below, the heat transfer fluid rejects heat to the MCM in heat pump 106. The now cooler heat transfer fluid flows by line 126 to first heat exchanger 104 to receive heat from wash chamber 106 of tub 104 and repeat the cycle as just described. Pump 102 connected into line 124 causes the heat transfer fluid to circulate in heat pump system 100. Motor 110 is in mechanical communication with heat pump 106 as will further described. During operation of heat pump system 100, the heat transfer fluid may not undergo a phase change.

Heat pump system 100 is provided by way of example only. Other configurations of heat pump system 100 may be used as well. For example, lines 120, 122, 124 and 126 provide fluid communication between the various components of heat pump system 100 but other heat transfer fluid recirculation loops with different lines and connections may also be employed. For example, pump 102 can also be positioned at other locations or on other lines in heat pump system 100. Still other configurations of heat pump system 100 may be used as well. Heat pump 106 may be any suitable heat pump with MCM. For example, heat pump 106 may be constructed or arranged in the manner described in U.S. Patent Publication No. 2014/0165594 of Michael Alexander Benedict, which is hereby incorporated by reference in its entirety.

Operation of heat pump system 100 in the heating mode will now be described. In the heating mode, the heat transfer fluid flows out of first heat exchanger 104 by line 126 to heat pump 106 after heating wash chamber 106 of tub 104. As will be further described herein, the heat transfer fluid rejects additional heat to magneto-caloric material (MCM) in heat pump 106 and then flows by line 122 to second heat exchanger 108, e.g., that is disposed within machinery compartment 140. The heat transfer fluid within second heat exchanger 108 is heated by the environment, machinery compartment 140, and/or another location external to wash chamber 106 of tub 104 via second heat exchanger 108. Fan 112 may be used to create a flow of air across second heat exchanger 108 and thereby improve the rate of heat transfer from the environment.

From second heat exchanger 108, the heat transfer fluid returns by line 124 to pump 102 and then to heat pump 106 where, as will be further described below, the heat transfer fluid receives heat from the MCM in heat pump 106. The now hotter heat transfer fluid flows by line 120 to first heat exchanger 104 to reject heat to wash chamber 106 of tub 104 and repeat the cycle as just described.

Ice making appliance 10 also includes a temperature sensor 92. Temperature sensor 92 is configured for measuring a temperature within interior volume 56 of casing 52. Temperature sensor 92 can be positioned at any suitable location within ice making appliance 10. For example, temperature sensor 92 may be positioned within interior volume 56 of casing 52 or may be mounted to casing 52 outside of interior volume 56 of casing 52. When mounted to casing 52 outside of interior volume 56 of casing 52, temperature sensor 92 can be configured for indirectly measuring the temperature of water within interior volume 56 of casing 52. For example, temperature sensor 92 can measure the temperature of casing 52 and correlate the temperature of casing 52 to the temperature of interior volume 56 of casing 52. Temperature sensor 92 can be any suitable temperature sensor. For example, temperature sensor 92 may be a thermocouple or a thermistor.

Controller 90 is in, e.g., operative, communication with pump 102, motor 110, fan 112 and temperature sensor 92. Thus, controller 90 can selectively activate pump 102 and motor 110 in order to cool or heat interior volume 56 of casing 52, e.g., in response to temperature measurements from temperature sensor 92.

FIGS. 5 through 8 depict various views of an exemplary heat pump 200 of as may be used with the present subject matter. Thus, heat pump 200 may be utilized within ice making appliance 10 as heat pump 106. Heat pump 200 is provided by way of example only and is not intended to limit the present subject matter to any particular heat pump. As will be understood, any other suitable heat pump, such as a linearly actuating heat pump, may be utilized within ice making appliance 10 as heat pump 106 in alternative exemplary embodiments.

Heat pump 200 includes a regenerator housing 202 that extends longitudinally along an axial direction between a first end 218 and a second end 220. The axial direction is defined by axis A-A about which regenerator housing 202 is rotatable. A radial direction R is defined by a radius extending orthogonally from the axis of rotation A-A (FIG. 7). A circumferential direction is indicated by arrows C.

Regenerator housing 202 defines a plurality of chambers 204 that extend longitudinally along the axial direction defined by axis A-A. Chambers 204 are positioned proximate or adjacent to each other along circumferential direction C. Each chamber 204 includes a pair of openings 206 and 208 positioned at opposing ends 218 and 220 of regenerator housing 202.

Heat pump 200 also includes a plurality of stages 212 that include MCM. Each stage 212 is located in one of the chambers 204 and extends along the axial direction. For the exemplary embodiment shown in the figures, heat pump 200 includes eight stages 212 positioned adjacent to each other along the circumferential direction as shown and extending longitudinally along the axial direction. As will be understood by one of skill in the art using the teachings disclosed herein, a different number of stages 212 other than eight may be used as well.

A pair of valves 214 and 216 is attached to regenerator housing 202 and rotates therewith along circumferential direction C. More particularly, a first valve 214 is attached to first end 218 and a second valve 216 is attached to second end 220. Each valve 214 and 216 includes a plurality of apertures 222 and 224, respectively. For this exemplary embodiment, apertures 222 and 224 are configured as circumferentially-extending slots that are spaced apart along circumferential direction C. Each aperture 222 is positioned adjacent to a respective opening 206 of a chamber 204. Each aperture 224 is positioned adjacent to a respective opening 208 of a chamber 204. Accordingly, a heat transfer fluid may flow into a chamber 204 through a respective aperture 222 and opening 206 so as to flow through the MCM in a respective stage 212 and then exit through opening 208 and aperture 224. A reverse path can be used for flow of the heat transfer fluid in the opposite direction through the stage 212 of a given chamber 204.

Regenerator housing 202 defines a cavity 228 that is positioned radially inward of the plurality of chambers 204 and extends along the axial direction between first end 218 and second end 220. A magnetic element 226 is positioned within cavity 228 and, for this exemplary embodiment, extends along the axial direction between first end 218 and second end 220. Magnetic element 226 provides a magnetic field that is directed radially outward as indicated by arrows M in FIG. 7.

The positioning and configuration of magnetic element 226 is such that only a subset of the plurality of stages 212 is within magnetic field M at any one time. For example, as shown in FIG. 7, stages 212 a and 212e are partially within the magnetic field while stages 212 b, 212 c, and 212 d are fully within the magnetic field M created by magnetic element 226. Conversely, the magnetic element 226 is configured and positioned so that stages 212 f, 212 g, and 212 h are completely or substantially out of the magnetic field created by magnetic element 226. However, as regenerator housing 202 is continuously rotated along the circumferential direction as shown by arrow W, the subset of stages 212 within the magnetic field will continuously change as some stages 212 will enter magnetic field M and others will exit.

A pair of seals 236 and 238 is provided with the seals positioned in an opposing manner at the first end 218 and second end 220 of regenerator housing 202. First seal 236 has a first inlet port 240 and a first outlet port 242 and is positioned adjacent to first valve 214. As shown, ports 240 and 242 are positioned 180 degrees apart about the circumferential direction C of first seal 214. However, other configurations may be used. For example, ports 240 and 242 may be positioned within a range of about 170 degrees to about 190 degrees about the circumferential direction C as well. First valve 214 and regenerator housing 202 are rotatable relative to first seal 236. Ports 240 and 242 are connected with lines 120 and 122 (FIG. 5), respectively. As such, the rotation of regenerator housing 202 about axis A-A sequentially places lines 120 and 122 in fluid communication with at least two stages 212 of MCM at any one time as will be further described.

Second seal 238 has a second inlet port 244 and a second outlet port 246 and is positioned adjacent to second valve 216. As shown, ports 244 and 246 are positioned 180 degrees apart about the circumferential direction C of second seal 216. However, other configurations may be used. For example, ports 244 and 246 may be positioned within a range of about 170 degrees to about 190 degrees about the circumferential direction C as well. Second valve 216 and regenerator housing 202 are rotatable relative to second seal 238. Ports 244 and 246 are connected with lines 126 and 124 (FIG. 5), respectively. As such, the rotation of regenerator housing 202 about axis A-A sequentially places lines 124 and 126 in fluid communication with at least two stages 212 of MCM at any one time as will be further described. Notably, at any one time during rotation of regenerator housing 202, lines 122 and 126 will each be in fluid communication with at least one stage 212 while lines 120 and 124 will also be in fluid communication with at least one other stage 212 located about 180 degrees away along the circumferential direction.

FIG. 9 illustrates an exemplary method using a schematic representation of stage 212 of MCM in regenerator housing 202 as it rotates in the direction of arrow W between positions 1 through 8 as shown in FIG. 8. As will be understood, other suitable arrangements of heat pump 106 (e.g., linear motion of stages 212 of MCM) may be utilized to provide similar heating and cooling of the heat transfer fluid, e.g., via the magneto-caloric effect in stages 212 of MCM. During step 800, stage 212 is fully within magnetic field M, which causes the magnetic moments of the material to orient and the MCM to heat as part of the magneto-caloric effect. Ordering of the magnetic field is created and maintained as stage 212 is rotated sequentially through positions 2, 3, and then 4 (FIG. 8) as regenerator housing 202 is rotated in the direction of arrow W. During the time at positions 2, 3, and 4, the heat transfer fluid dwells in the MCM of stage 212 and, therefore, is heated. More specifically, the heat transfer fluid does not flow through stage 212 because the openings 206, 208, 222, and 224 corresponding to stage 212 in positions 2, 3, and 4 are not aligned with any of the ports 240, 242, 244, or 246.

In step 802, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 will eventually reach position 5. As shown in FIGS. 5 and 8, at position 5 the heat transfer fluid can flow through the material as first inlet port 240 is now aligned with an opening 222 in first valve 214 and an opening 206 at the first end 218 of stage 212 while second outlet port 246 is aligned with an opening 224 in second valve 216 at the second end 220 of stage 212. As indicated by arrow Q_(H-OUT), heat transfer fluid in stage 212, now heated by the MCM, can travel out of regenerator housing 202 and along line 124 to the second heat exchanger 108. At the same time, and as indicated by arrow Q_(H-IN), heat transfer fluid from first heat exchanger 104 flows into stage 212 from line 120 when stage 212 is at position 5. Because heat transfer fluid from the first heat exchanger 104 is relatively cooler than the MCM in stage 212, the MCM rejects heat to the heat transfer fluid.

Referring again to FIG. 9 and step 804, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 is moved sequentially through positions 6, 7, and 8 where stage 212 is completely or substantially out of magnetic field M. The absence or lessening of the magnetic field is such that the magnetic moments of the material become disordered and the MCM absorbs heat as part of the magneto-caloric effect. During the time in positions 6, 7, and 8, the heat transfer fluid dwells in the MCM of stage 212 and, therefore, is cooled by losing heat to the MCM as the magnetic moments disorder. More specifically, the heat transfer fluid does not flow through stage 212 because the openings 206, 208, 222, and 224 corresponding to stage 212 when in positions 6, 7, and 8 are not aligned with any of the ports 240, 242, 244, or 246.

Referring to step 806 of FIG. 9, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 will eventually reach position 1. As shown in FIGS. 5 and 8, at position 1 the heat transfer fluid in stage 212 can flow through the material as second inlet port 244 is now aligned with an opening 224 in second valve 216 and an opening 208 at the second end 220 while first outlet port 242 is aligned with an opening 222 in first valve 214 and opening 206 at first end 218. As indicated by arrow Q_(C-OUT), heat transfer fluid in stage 212, now cooled by the MCM, can travel out of regenerator housing 202 and along line 126 to the first heat exchanger 104. At the same time, and as indicated by arrow Q_(C-IN), heat transfer fluid from second heat exchanger 108 flows into stage 212 from line 122 when stage 212 is at position 1. Because heat transfer fluid from the second heat exchanger 108 is relatively warmer than the MCM in stage 212 at position 1, the MCM will be heated by the heat transfer fluid. The heat transfer fluid now travels along line 126 to the first heat exchanger 104 to receive additional heat and thereby cool casing 52.

As regenerator housing 202 is rotated continuously, the above described process of placing stage 212 in and out of magnetic field M is repeated. Additionally, the size of magnetic field M and regenerator housing 202 are such that a subset of the plurality of stages 212 is within the magnetic field at any given time during rotation. Similarly, a subset of the plurality of stages 212 are outside (or substantially outside) of the magnetic field at any given time during rotation. Additionally, at any given time, there are at least two stages 212 through which the heat transfer fluid is flowing while the other stages remain in a dwell mode. More specifically, while one stage 212 is receiving heat through the flow of heat transfer fluid at position 1, another stage 212 is losing heat from the flowing heat transfer fluid at position 5, while all remaining stages 212 are in dwell mode. As such, the system can be operated continuously to provide a continuous recirculation of heat transfer fluid in heat pump system 100 as stages 212 are each sequentially rotated through positions 1 through 8.

Utilizing the exemplary method of FIG. 9, interior volume 56 of casing 52 may be cooled by heat transfer fluid within first heat exchanger 104. Such cooling of interior volume 56 of casing 52 may assist with forming ice on the inner surface of casing 52 at interior volume 56 of casing 52. As discussed in greater detail below, interior volume 56 of casing 52 may also be heated by heat transfer fluid within first heat exchanger 104. Such heating of interior volume 56 of casing 52 may assist with deicing casing 52, e.g., when rotation of auger 60 is blocked or hindered by ice within interior volume 56 of casing 52.

FIG. 10 illustrates an exemplary method using a schematic representation of stage 212 of MCM in regenerator housing 202 as it rotates in the direction of arrow W between positions 1 through 8 as shown in FIG. 8. To adjust between the operations of heat pump 200 shown in FIGS. 9 and 10, pump 102 may be reversed or a valve within heat pump system 100 may actuated to reverse the direction of heat transfer fluid flow within heat pump system 100. Thus, pump 102 may be a reversible pump in certain exemplary embodiments. In alternative exemplary embodiments, heat pump system 100 may include a valve(s) for reversing fluid flow through heat pump system 100, e.g., rather than reversing the direction of pump 102. Thus, heat pump system 100 may be adjusted between the cooling and heating operations by reversing pump 102 or actuating suitable valve(s).

During step 900, stage 212 is fully within magnetic field M, which causes the magnetic moments of the material to orient and the MCM to heat as part of the magneto-caloric effect. Ordering of the magnetic field is created and maintained as stage 212 is rotated sequentially through positions 2, 3, and then 4 (FIG. 8) as regenerator housing 202 is rotated in the direction of arrow W. During the time at positions 2, 3, and 4, the heat transfer fluid dwells in the MCM of stage 212 and, therefore, is heated. More specifically, the heat transfer fluid does not flow through stage 212 because the openings 206, 208, 222, and 224 corresponding to stage 212 in positions 2, 3, and 4 are not aligned with any of the ports 240, 242, 244, or 246.

In step 902, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 will eventually reach position 5. At position 5, the heat transfer fluid can flow through the material as first inlet port 240 is now aligned with an opening 222 in first valve 214 and an opening 206 at the first end 218 of stage 212 while second outlet port 246 is aligned with an opening 224 in second valve 216 at the second end 220 of stage 212. Heat transfer fluid in stage 212, now heated by the MCM, can travel out of regenerator housing 202 and along line 120 to first heat exchanger 104. At the same time, heat transfer fluid from second heat exchanger 108 flows into stage 212 from line 124 when stage 212 is at position 5. Because heat transfer fluid from the second heat exchanger 108 is relatively cooler than the MCM in stage 212, the MCM rejects heat to the heat transfer fluid.

At step 904, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 is moved sequentially through positions 6, 7, and 8 where stage 212 is completely or substantially out of magnetic field M. The absence or lessening of the magnetic field is such that the magnetic moments of the material become disordered and the MCM absorbs heat as part of the magneto-caloric effect. During the time in positions 6, 7, and 8, the heat transfer fluid dwells in the MCM of stage 212 and, therefore, is cooled by losing heat to the MCM as the magnetic moments disorder. More specifically, the heat transfer fluid does not flow through stage 212 because the openings 206, 208, 222, and 224 corresponding to stage 212 when in positions 6, 7, and 8 are not aligned with any of the ports 240, 242, 244, or 246.

Referring to step 906 of FIG. 10, as regenerator housing 202 continues to rotate in the direction of arrow W, stage 212 will eventually reach position 1 (FIG. 8). At position 1, the heat transfer fluid in stage 212 can flow through the material as second inlet port 244 is now aligned with an opening 224 in second valve 216 and an opening 208 at the second end 220 while first outlet port 242 is aligned with an opening 222 in first valve 214 and opening 206 at first end 218. Heat transfer fluid in stage 212, now cooled by the MCM, can travel out of regenerator housing 202 and along line 122 to the second heat exchanger 108. At the same time, heat transfer fluid from first heat exchanger 104 flows into stage 212 from line 126 when stage 212 is at position 5. Because heat transfer fluid from the first heat exchanger 104 is relatively warmer than the MCM in stage 212 at position 5, the MCM will be heated by the heat transfer fluid. The heat transfer fluid now travels along line 122 to the second heat exchanger 108 to receive additional heat.

As will be understood by one of skill in the art using the teachings disclosed herein, the number of stages for housing 202, the number of ports in valve 214 and 216, and/or other parameters can be varied to provide different configurations of heat pump 200 while still providing for continuous operation. For example, each valve could be provided within two inlet ports and two outlet ports so that heat transfer fluid flows through at least four stages 212 at any particular point in time. Alternatively, regenerator housing 202, valves 222 and 224, and/or seals 236 and 238 could be constructed so that e.g., at least two stages are in fluid communication with an inlet port and outlet port at any one time. Other configurations may be used as well.

As stated, stage 212 includes MCM extending along the axial direction of flow. The MCM may be constructed from a single magneto caloric material or may include multiple different magneto caloric materials. By way of example, ice making appliance 10 may be used in an application where the ambient temperature changes over a substantial range. However, a specific magneto caloric material may exhibit the magneto caloric effect over only a much narrower temperature range. As such, it may be desirable to use a variety of magneto caloric materials within a given stage to accommodate the wide range of ambient temperatures over which ice making appliance 10 and/or heat pump 200 may be used.

A motor 110 is in mechanical communication with regenerator housing 202 and provides for rotation of housing 202 about axis A-A. By way of example, motor 110 may be connected directly with housing 202 by a shaft or indirectly through a gear box. Other configurations may be used as well.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An ice making appliance, comprising: a casing; an auger disposed within the casing; a motor coupled to the auger, the motor operable to rotate the auger within the casing; a first heat exchanger coupled to the casing for receiving heat from the casing; a second heat exchanger; and a caloric heat pump system configured for cooling the casing with the first heat exchanger, the caloric heat pump system comprising a plurality of caloric material stages; a field generator positioned proximate the caloric material stages, the field generator positioned such that the caloric material stages are moved in and out of a field of the field generator during operation of the caloric heat pump system; and a pump for circulating a heat transfer fluid between the first and second heat exchangers and the caloric material stages.
 2. The ice making appliance of claim 1, wherein the pump is a reversible pump.
 3. The ice making appliance of claim 2, wherein the caloric heat pump system is further configured for heating the casing with the first heat exchanger by reversing operation of the pump.
 4. The ice making appliance of claim 1, wherein the first heat exchanger comprises a conduit wound around the casing on an outer surface of the casing.
 5. The ice making appliance of claim 4, wherein adjacent windings of the conduit are spaced apart from one another along a vertical direction on the outer surface of the casing.
 6. The ice making appliance of claim 5, wherein the adjacent windings of the conduit are uniformly spaced apart from one another along the vertical direction.
 7. The ice making appliance of claim 5, wherein an inlet of the conduit is positioned at a bottom portion of the casing and an outlet of the conduit is positioned at a top portion of the casing, the inlet of the conduit being in fluid communication with at least one of the caloric material stages such that the inlet of the conduit is configured to receive circulating heat transfer fluid from the at least one of the caloric material stages.
 8. The ice making appliance of claim 1, wherein the heat transfer fluid comprises water.
 9. The ice making appliance of claim 1, further comprising a container defining a first storage volume for receipt of ice; a water tank defining a second storage volume for receipt of liquid water; a second pump operable to flow liquid water from the second storage volume; a reservoir defining a third storage volume, the third storage volume in fluid communication with the second pump for receiving liquid water from the water tank; and a chute positioned for receiving ice from the casing and directing the ice into the first storage volume.
 10. The ice making appliance of claim 8, further comprising an extruder mounted to the casing.
 11. The ice making appliance of claim 1, wherein the water tank is disposed below the container along a vertical direction.
 12. An appliance, comprising: an ice maker; a first heat exchanger coupled to the ice maker for receiving heat; a second heat exchanger; and a caloric heat pump system configured for cooling the ice maker with the first heat exchanger, the caloric heat pump system comprising a plurality of caloric material stages; a field generator positioned proximate the caloric material stages, the field generator positioned such that the caloric material stages are moved in and out of a field of the field generator during operation of the caloric heat pump system; and a pump for circulating a heat transfer fluid between the first and second heat exchangers and the caloric material stages.
 13. The appliance of claim 12, wherein the pump is a reversible pump.
 14. The appliance of claim 13, wherein the caloric heat pump system is further configured for heating the ice maker with the first heat exchanger by reversing operation of the pump.
 15. The appliance of claim 12, wherein the first heat exchanger comprises a conduit wound around a casing of the ice maker on an outer surface of the casing.
 16. The appliance of claim 15, wherein adjacent windings of the conduit are spaced apart from one another along a vertical direction on the outer surface of the casing.
 17. The appliance of claim 16, wherein an inlet of the conduit is positioned at a bottom portion of the casing and an outlet of the conduit is positioned at a top portion of the casing, the inlet of the conduit being in fluid communication with at least one of the caloric material stages such that the inlet of the conduit is configured to receive circulating heat transfer fluid from the at least one of the caloric material stages.
 18. The appliance of claim 12, wherein the heat transfer fluid comprises water.
 19. The appliance of claim 12, further comprising a container defining a first storage volume for receipt of ice; a water tank defining a second storage volume for receipt of liquid water; a second pump operable to flow liquid water from the second storage volume; a reservoir defining a third storage volume, the third storage volume in fluid communication with the second pump for receiving liquid water from the water tank; and a chute positioned for receiving ice from the ice maker and directing the ice into the first storage volume.
 20. The appliance of claim 12, wherein the water tank is disposed below the container along a vertical direction. 